Aero-engine rectifier is characterized by dense cascades

narrow channel space and poor structural openness. A series of studies with precise vibrating electrochemical machining process were carried out for nickel-base superalloy rectifiers. By coupling high-frequency pulse with low-frequency vibration

batch optimization of cathode surface profiles

physical model of flow field simulation and analysis

uniform and stable machining state of small gap was obtained. The optimized process parameters were obtained by orthogonal test. The parameters are voltage of 15V

cathode vibrating frequency of 20Hz

opening angle of 160°–190°

pulse frequency of 3000Hz. Rectifier blades were produced with profile tolerance of – 0.023

~ + 0.025mm and roughness R

a

of 0.55μm. No intergranular and pitting corrosion was observed by SEM. And no matal elements were selectively removed by EDS. The manufactured nickel-base superalloy rectifier had passed the high cycle fatigue test and had been successfully applied to aero-engine. This provides provides technical support for the manufacture of complex monolithic components with difficult-to-machining materials.